User’s Guide AB1746-C Network Master (Version 5.21) For Allen-Bradley Series SLC-500 Programmable Controllers (Date: 2004-11-18) Controlinc 1746-C (Version 5.21) Network Master Users Guide (2004-11-18) User’s Guide Controlinc Network Master … AB1746-C (Version 5.21) For Allen-Bradley Series SLC-500 Programmable Controllers Table of Contents 0. Quick Start Information...............................................................................1 1. Introduction...................................................................................................2 1.1. Overview of 1746-C System...................................................................................2 1.2. Overview of Changes in Version 5.21...................................................................4 1.3. Reference Manuals .................................................................................................5 1.4. EIM Equipment Compatibility .............................................................................6 1.5. Firmware .................................................................................................................6 2. 1746-C Hardware..........................................................................................7 2.1. Hardware Setup......................................................................................................7 2.2. LED Utilization.......................................................................................................8 2.2.1. Green (PRT1 & PRT2) and Yellow (LED1 & LED2) LED Usage...........................8 2.2.2. Red “BA LOW” LED Usage.................................................................................10 3. Network Setup and Connecting to the NIU..............................................11 3.1. Field Connections at the Actuator.......................................................................13 3.1.1. Step 1. Plan the Network Topology...................................................................13 3.1.2. Step 2. Select Network Cable............................................................................13 3.1.3. Step 3. Route Cable away from Electrical Interference.....................................14 3.1.4. Step 4. Observe Polarity and Network Grounding.............................................14 3.1.5. Step 5. Wire Preparation and Connections........................................................14 3.1.6. Step 6. Test Network.........................................................................................14 3.2. Field Network Cable Connection to the NIU.....................................................15 3.3. Cable Connection Between the NIU and the Network Master ........................15 4. 1746-C General Theory of Operation .......................................................16 4.1. Operational Overview..........................................................................................16 4.1.1. Diagram Describing Relationship Between Process Time Slices........................16 Copyright © 2004 EIM COMPANY, INC. • 13840 PIKE ROAD • MISSOURI CITY, TX. 77489 Page i Controlinc 1746-C (Version 5.21) Network Master Users Guide (2004-11-18) 4.1.2. Diagram Describing Network Scanning & Actuator Writing Logic........................17 4.1.3. Diagram Demonstrating Adding Additional Valves in Valve Scan Time-Slice......18 4.1.4. Diagram Describing Relationship Between Scan Period & Diagnostic Scan.......19 4.1.5. 1746-C System Operations at Power Up.............................................................20 4.2. Network Interface (Scan) Time-Slice (1746-C ↔ Network Communication)21 4.2.1. Operation: Network Scanning to Gather Valve Actuator Data............................21 4.2.2. Operation: The Network Communication Diagnostic Scan.................................22 4.3. PLC Interface Time-Slice (1746-C ↔ PLC Communication)..........................24 4.3.1. Operation: PLC (Write Data Tables To) or (Read Tables From) the 1746-C......26 4.3.2. Operation: PLC Commands to Write Data to the Actuators................................29 4.3.3. RLL Example … Manually Send New Table … Auto Read Response................31 5. System Tables..............................................................................................33 5.1. Table Arrangement...............................................................................................35 5.2. Standard Header Format (All Tables) … Words [0 (cid:198) 3]................................37 5.2.1. Word [0]: Table ID.............................................................................................37 5.2.2. Word [1]: Read / Write Command Indicator......................................................37 5.2.3. Word [2]: Reserved / Firmware ID.....................................................................37 5.2.4. Word [3]: Emergency Shut Down (ESD) Command Word & Indication ............38 5.3. Table [0] … System Information Table..............................................................39 5.3.1. Table [0] Overview...............................................................................................39 5.3.2. Table [0] Configuration Words … Words [4(cid:198) 17]................................................42 5.3.3. Table [0] Run-Time Information Words … Words [47(cid:198) 63] ................................47 5.3.4. Table [0] … RSLOGIX-500 Examples.................................................................48 5.3.4.1. Example RSLOGIX-500 Screen:..........................................................................48 5.3.4.2. Table [0] … The Configuration Values (RSLOGIX-500)......................................49 5.3.4.3. Table [0] … The Configuration Values – Writing Table [0] (RSLOGIX-500)........50 5.3.4.4. Table [0] … The Run-Time Feedback Values From 1746-C (RSLOGIX-500).....51 5.4. Tables [1 (cid:198) 20] … Actuator Information Tables..............................................52 5.4.1. Table [1]: Communication Error Status...............................................................52 5.4.2. Table [2]: Actuator Operational Status................................................................54 5.4.3. Table [3]: Discrete Control Mode (Open/Close/Stop) .........................................56 5.4.4. Table [4]: Valve Position Indication … 0 – 100.0%.............................................58 5.4.5. Table [5]: Valve Position Setpoint … 0 – 4095...................................................59 5.4.6. Tables [6 & 7]: User Analog Inputs #1 & 2..........................................................61 5.4.7. Table [8]: Analog Output #1................................................................................62 5.4.8. Tables [9 & 10]: Digital Input Accumulators (Totalizers) #1 & 2..........................64 5.4.9. Table [11]: Valve Position Indication … 0 – 4095...............................................66 5.4.10. Table [12]: Discrete Input Statuses...................................................................67 5.4.11. Table [13]: Solid State Relay (SSR) Configuration Table.................................69 Copyright © 2004 EIM COMPANY, INC. • 13840 PIKE ROAD • MISSOURI CITY, TX. 77489 Page ii Controlinc 1746-C (Version 5.21) Network Master Users Guide (2004-11-18) 5.4.12. Table [14]: Additional Register Being Polled From Entire Network...................71 5.4.13. Table [15]: Additional Block of Registers Being Polled From 1 Actuator...........73 5.4.14. Tables [16 & 17]: Monitor & Control Discrete Digital Outputs...........................76 5.4.15. Table [18]: Actuator System Type ID................................................................81 5.4.16. Table [19]: Actuator Firmware Version ID.........................................................83 5.4.17. Table [20]: Modbus Exception Message Response..........................................84 5.4.18. Tables [21-24]: TEC2000 Status Inputs............................................................86 6. Application Notes........................................................................................88 6.1. App Note: Performance Tuning.........................................................................88 6.1.1. General Practices to Ensure Better Performance................................................88 6.1.2. Reading Run-Time Information from Table [0].....................................................88 6.1.3. Loading Table [0] with Configuration Information................................................89 6.1.4. Behavior if a Delay in Loading Table [0] Configuration Information.....................90 6.1.5. Using the “Scan Period” Value ............................................................................91 6.2. App Note: 1746-C Operation – Additional Detailed Information..................92 6.2.1. Scan Operation: Determining & Exiting “Network Down” Condition....................92 6.2.2. Detailed Description of 1746-C Operation...........................................................93 6.2.3. Time Allocated Process Control (Allocated Time Slices).....................................94 6.2.4. Preferred Communication Port Operation............................................................96 6.2.5. Communication Failure Indications (Low-Level & High-Level).............................97 6.2.6. Bringing Units On-Line After a Power Cycle......................................................100 6.2.7. Toggling the Preferred Port to Assist Diagnostics .............................................101 6.3. App Note: For Diagnostics - Know the Physical Network Wiring...............102 6.4. App Note: Memory Maps .................................................................................103 6.4.1. Specific Holding Registers Referenced by the Network Master.........................103 6.4.2. Specific Coils & Inputs Referenced by the Network Master...............................104 6.4.3. 320A Memory Map … Table for Coils & Inputs (Version 2.0)............................105 6.4.4. 320A Memory Map … Addressable Holding Registers (Version 2.0)................106 6.4.5. 320B Memory Map … Table for Coils & Inputs..................................................108 6.4.6. 320B Memory Map … Addressable Holding Registers......................................109 6.4.7. TEC2000 Memory Map … Table for Coils & Inputs...........................................111 6.4.8. TEC2000 Memory Map … Table for Holding Registers.....................................112 6.5. App Note: Modbus Message Formats..............................................................117 6.5.1. Modbus RTU Functions (Command Codes) Implemented................................117 6.5.2. Modbus Function (Command) Code Descriptions.............................................118 6.5.2.1. Modbus Function Code 01 … Read Coil Status.................................................118 6.5.2.2. Modbus Function Code 03 … Read Holding Register........................................119 6.5.2.3. Modbus Function Code 05 … Set (Force) Single Coil........................................120 6.5.2.4. Modbus Function Code 06 … Set Single Register.............................................121 6.5.2.5. Modbus Function Code 15 (0x0F) … Set (Force) Multiple Coils........................122 Copyright © 2004 EIM COMPANY, INC. • 13840 PIKE ROAD • MISSOURI CITY, TX. 77489 Page iii Controlinc 1746-C (Version 5.21) Network Master Users Guide (2004-11-18) 6.5.3. Modbus Exception Messages Supported..........................................................123 6.6. App Note: Install the 1746-C Network Master Firmware.............................124 6.6.1. Configure the Module for a Firmware Upload....................................................124 6.6.2. Upload the 1746-C Firmware.............................................................................125 6.6.3. Reset the 1746-C Module for Normal Operations..............................................126 Copyright © 2004 EIM COMPANY, INC. • 13840 PIKE ROAD • MISSOURI CITY, TX. 77489 Page iv Controlinc 1746-C (Version 5.21) Network Master Users Guide (2004-11-18) 0. Quick Start Information 1. As a minimum, you should have access to the following reference documents: • This manual (1746-C User’s Guide) • Allen-Bradley SLC-500 BASIC User's Manual (1746-BAS & 1746-BAS-T) Publication No. 1746-UM004A-US-P 2000 • EIM Controlinc 320A Quick Startup Guide, Rev. F or later • EIM Controlinc 320B Quick Startup Guide, Rev. A or later 2. Refer to Section 2 of this manual on how the jumpers should be set on the BASIC module. 3. The 1746-C module comes from EIM pre-programmed with the network master program in it. However, if for some reason the module needs to be flashed again (ex: a field upgrade) then refer to Section 5 on installing the firmware in the module. Note: Remember, you will need to connect a serial cable between the 1746-C and the computer. The correct cable is a Null Modem Cable connected between the PRT1 port (top DB9 connector on the module) and the serial communications port on the computer used for the upload. 4. Ensure the PLC rack power is turned off. Install the module in the correct slot in the PLC rack. Connect all cables and power the system up. 5. The PLC-RLL will start interfacing with the 1746-C after the 1746-C performs initial scans of the network on power up. NOTES: To ensure optimal performance, some things the PLC should do … 1. Ensure table [0] is set correctly and repeated in a timely manner. Allow for frequent table [0] read backs. 2. Restrict the rate of data writes to the actuators … only write as fast as required to adequately control the valve. (cuts down on the interruptions to scanning the network … gathering data) 3. Expedite responses to M1 transfer requests made by the 1746-C. Delaying them can slow 1746-C operations. 4. Only activate writing to or reading from tables if actually in use (or when needed). (ex: do not write to the analog output table if analog outputs are not used) (ex: do not read totalizer data if its not being used) (ex: only poll for “static” [non-changing] data one time and stop) (prevents unnecessary delays to gathering the more important data from the network) Remember: The 1746-C uses explicit read/write commanding of the tables such that if word [1] in any table is zero (0) then it is a table read request by the PLC. Otherwise, the command is a table write command. Copyright © 2004 EIM COMPANY, INC. • 13840 PIKE ROAD • MISSOURI CITY, TX. 77489 Page 1 Controlinc 1746-C (Version 5.21) Network Master Users Guide (2004-11-18) 1. Introduction 1.1. Overview of 1746-C System This document is intended for end users as a Guide in applying an EIM AB 1746-C Network Master. The software that enables network operation is called a communication driver. It is used in conjunction with an Allen-Bradley 1746-BAS module thereby creating the 1746-C network master module. The 1746-C allows an AB SLC-500 controller to acquire data from and send information to an EIM Controlinc Actuator Network. GENERAL SYSTEM PURPOSE: The EIM 1746-C network master serves as a data concent rator for applications that use an AB SLC-500 Programmable Logic Controller (PLC). The 1746-C module must be located in a slot in the local chassis (it cannot be mounted in a chassis that is remote from the SLC CPU). In general, the network master off-loads network communication and management SLC-500 with 1746-C installed 1746-C tasks from the actual controlling equipment. The main function of the 1746-C is to provide the interface between a PLC and its network of valve actuators. Acting as a Host, the PLC controls the network by sending data to the 1746-C for routing to a particular actuator. The 1746-C network master polls the individual actuators for information and makes it available to the PLC when requested. A typical ring topology network and network master are illustrated in Figure 1. The 1746-C module serves as a master within this Modbus (Modbus RTU) master/slave network. The module will manage network operation by keeping an orderly cycle of data transfers between itself and each slave (valve actuator). Figure 1 Copyright © 2004 EIM COMPANY, INC. • 13840 PIKE ROAD • MISSOURI CITY, TX. 77489 Page 2 Controlinc 1746-C (Version 5.21) Network Master Users Guide (2004-11-18) The 1746-C master will handle network communication, error detection, alarming, and network recovery. Other features include: • Reporting of inaccessible actuators • Reporting of network faults • Emergency shutdown broadcasting • Minimal Interfacing with the Relay Ladder Logic (RLL) program in the PLC CPU module Each 1746-C module can support a single network of up to 60 valve actuators. Multiple modules can be installed in an SLC-500 system rack to provide support for multiple networks (up to 60 actuators each). Note 1: It is important to note that the 1746-C Network Master may be used in any slot of the 1746 rack, not just slot 1 next to the SLC-500 CPU. Copyright © 2004 EIM COMPANY, INC. • 13840 PIKE ROAD • MISSOURI CITY, TX. 77489 Page 3 Controlinc 1746-C (Version 5.21) Network Master Users Guide (2004-11-18) 1.2. Overview of Changes in Version 5.21 For the 1746-C system, there is no previous version of the product to reflect functional changes to. However, any later releases of this document for this version of the product (5.21) are to only correct entries in this document … primarily grammatical or “typos” that are discovered in the future. Major ideas will be documented with a separate “line entry”. Major document changes: 1. This document: 2004-11-18 Previous document: 2004-08-17 Major Change: Memory Maps adjusted. 2. New document: 2004-08-17 Previous document: 2004-08-06 Major Changes: Memory Maps adjusted and this section added. Copyright © 2004 EIM COMPANY, INC. • 13840 PIKE ROAD • MISSOURI CITY, TX. 77489 Page 4 Controlinc 1746-C (Version 5.21) Network Master Users Guide (2004-11-18) 1.3. Reference Manuals • Allen-Bradley SLC-500 BASIC User's Manual (1746-BAS & 1746-BAS-T) Publication No. 1746-UM004A-US-P 2000 This manual is required for installing the module and for proper uploading of this driver into the hardware. • EIM … Controlinc 320A Quick Startup Guide, Rev. F or later Publication No. ECL-4004-0102 This manual is used for specific information on the Controlinc 320A Controller card located in the valve actuator. This includes networking, setup and available options. • EIM … Controlinc 320B Quick Startup Guide Publication No. ECL-4005-0404 This manual is used for specific information on the Controlinc 320B Controller card located in the valve actuator. This includes networking, setup and available options. • EIM … TEC2000 “Document … TBD” Publication No. ????????? At the time of this printing, this TEC2000 publication had not been made available. • Other Allen-Bradley manuals specific to the SLC-500 being applied. These may be required to implement the necessary Relay Ladder Logic (RLL) for application of the driver. For instance, this may include: o Allen Bradley SLC-500 Instruction Set Reference, Publication 1747-RM001D-EN-P (November-2003) This reference includes information in Appendix E on the M0 & M1 File Data Transfer handling. Copyright © 2004 EIM COMPANY, INC. • 13840 PIKE ROAD • MISSOURI CITY, TX. 77489 Page 5